Apparatus for production of pile carpeting

ABSTRACT

An improved process and technique for the manufacture of nonwoven pile fabrics is provided by an array of loop-forming members disposed in side-by-side relationship, the array of loopforming members being moved continuously or intermittently between a loop-forming station wherein a loop-forming member or blade descends between two adjacent loop-forming members to press yarns downwardly between said adjacent loop-forming members so as to form loops of yarn therebetween. Between the pair of loopforming members containing the immediately previously formed loops of yarn a gauge blade is inserted to a distance not greater than and preferably less than the distance said loop-forming blade descends into said first mentioned pair of loop-forming members so as to maintain said previously formed loops of yarn in position and/or at a desired depth between the loop-forming members containing the previously formed loops of yarn as said loop-forming blade descends to form additional loops of yarn.

United States Patent Adler 1451 Apr. 11, 1972 [54] APPARATUS FOR PRODUCTION OF Primary Examiner-Benjamin A. Borchelt PILE CARPETING Assistant Examiner--James V. Doramus Attorney-Robert S. Dunham, P. E. Henninger, Lester W. [72] Inventor: Ralph MtAdlel'iNew YorkiN-Y- Clark, Gerald W. Griffin, Thomas F. Moran, Howard J. [73] Assign; Adler process Corp" New York Churchill, R. Bradlee Boa], Christopher C. Dunham, Robert Scobey and Henry T. Burke [22] Filed: May 18, 1970 21 Appl. No.2 38,384 [57] ABSTRACT An improved process and technique for the manufacture of Related Apphcam Dam non-woven pile fabrics is provided by an array of loop-forming [63] continuatiomimpart f 793,342 Jam 24 members disposed in side-by-side relationship, the array of 1969, which is a continuatiomimpan f s loop-forming members being moved continuously or intermit- 520 402 Jam 13 19 p 3 424 32 tently between a loop-forming station wherein a loop-forming member or blade descends between two adjacent loop-form- 52 us. c1 ..156/435, 156/72, 139/2, ing members to Press yams downwardly between said adjacent 270/83 loop-forming members so as to form loops of yarn 51 1111.01 ..D04h11/08,D03d39/00 therebetweenthe P i P- members 58 Field of Search ..156/72, 435; 28/727, 72.5; cntaining immedlately PYeYwUSIY famed P 0f Yam 300/21 gauge blade 15 1nserted to a distance not greater than and preferably less than the distance said loop-forming blade [56] References Cited descends into said first mentioned pair of loop-forming members so as to maintain said previously formed loops of yarn in UNITED STATES PATENTS position and/or at a desired depth between the loop-forming members containing the previously formed loops of yarn as 3,424,632 I/ 1969 Adler ..l56/72 Said 1oop fol-ming blade descends to form additional loops of 3,309,252 3/1967 Adler yam 2,770,283 11/1956 Runton et a1. ..l56/435 10 Claims, 24 Drawing Figures PATENTEUAPR 11 m2 SHEET DBBF 12 INVEI VTOR. FAA/w /Z 4045? PATENTEDAPR 1 1 I972 SHEET OSUF 12 INVENTOR I ll FAA/w M 4045? Ha-w-q PATENTEDAPR 11 m2 3,655,490

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Tifillr {644/ 5 /V.' 4015? ANTIQUE) APPARATUS FOR PRODUCTION OF PILE CARPETING This application is a continuationdn-part of application Ser. No. 793,842, filed Jan. 24, 1969 which in turn is a continuation-in-partof my application Ser. No. 520,402 filed Jan. 13, 1966 entitled Method and Apparatus for Production of Pile Carpeting and the Like," now U.S. Pat. No. 3,424,632. The disclosures of the above-identified patent application and patent are herein incorporates and made part of this disclosure.

This invention relates to pile fabrics. More particularly, this invention relates to pile fabrics, such as carpeting, rugs and the like, and to a method and apparatus useful for producing same.

Various methods and apparatus have been employed for the production of pile fabrics, such as carpeting and rugs. Those methods and apparatus employing a weaving technique are capable of producing quality pile fabrics having a dense pile and long service or wearing life. Woven pile fabrics, however, are relatively expensive to produce and as a result woven pile fabrics are costly.

Pile fabrics and carpeting have also been prepared by utilizing non-weaving techniques, such as by knitting and by tufting. Pile fabrics produced by such techniques, however, generally exhibit a relatively loose pile and are less pleasing in appearance. Such pile fabrics, however, are capable of being produced at a relatively high rate and are usually less expensive as compared with woven pile fabrics.

The textile industry, particularly that portion thereof involved in the production of pile fabrics, such as carpeting and rugs, has long been interested in a fast, practical, inexpensive method and apparatus for the production of pile fabrics having a relatively dense pile and exhibiting a long wearing life and simulating a woven pile fabric. Techniques employed and suggested heretofore for the manufacture of such non-woven fabrics, however, have not been entirely satisfactory.

. Although techniques of making pile fabrics by forming loops of yarn between spaced, parallel, slat-like machine elements or loop-forming members have been investigated there has been relatively little commercial utilization of these techniques. Apparently the previously known and suggested techniques have failed to .meet the very demanding requirements of a commercially acceptable operation. It would appear that in order to gain commercial acceptance methods and apparatus for the production of non-woven pile fabrics must be capable of rapidly and continuously producing pile fabrics from diverse materials, natural and synthetic fibers, and of spun, twisted or monofilament yarns and in a variety of controlled pile heights, densities and patterns without requiring extensive alteration of the apparatus and basic method.

Accordingly, it is anobject of this invention to provide a method and apparatus for the production of pile fabric suitable for use as carpeting, rugs and the like and at a relatively high rate of production.

It is another object of this invention to provide an improved method and apparatus for the production of pile fabrics.

It is another object of this invention to provide a process and apparatus capable of producing pile fabric of uniform quality and at a production rate substantially in excess of that presently attainable for similar pile fabric.

In at least one embodiment of this invention at least one of FIGS. 4 and 5 illustrate in partial cross section other views of the actuating mechanism for the loop-forming blade and the gauge blade in an apparatus in accordance with this inventron;

FIGS. 6 and 7 illustrate in partial vertical cross section the operation of the loop-fon'ning blade and the gauge blade, respectively, in an apparatus in accordance with this inventlon;

FIGS. 8a, 8b, 8c, 8d and 8e illustrate sequentially the loopforming operation in an apparatus in accordance with this invention;

FIG. 9 illustrates in partial vertical cross section the loopforming mechanism and the loop-cutting mechanism in an apparatus in accordance with this invention;

FIGS. 10a, 10b and 100 show fragmentary cross sectional views of the loop-cutting element in an apparatus in ac cordance with this invention and illustrate the sequence of operations of this element;

FIGS. 11a and 11b illustrate in fragmentary perspective views the loop-cutting element in accordance with this invention;

FIG. 12 illustrates in perspective and partial cross section an array of the loop-forming elements suitable for use in an apparatus in accordance with this invention;

FIG. 13 is a fragmentary view of the carrier structure for the loop-forming elements in an apparatus in accordance with this invention;

FIG. 14 is a fragmentary cross sectional view showing the disposition of the loop-forming elements in an apparatus in accordance with this invention; and wherein FIG. 15 illustrates a supporting block in the carrier structure of the loop-forming elements in an apparatus in accordance with this invention.

In accordance with this invention there is provided a method and apparatus for the manufacture of non-woven pile fabrics useful as carpeting, rugs and the like. The pile of the fabric is produced by forming loops of yarn between slat-like loop-forming elements. The loop-forming elements are desirably arranged in a closed loop array in parallel side-byside disposition. The loops formed between the loop-forming elements, are, if desired, cut and a backing material applied thereto. Thereupon, the resulting pile fabric is removed from the array of loop-forming elements.

Desirably, the array of loop-forming elements is moved continuously and as the array of loop-forming elements moves beneath a loop-forming station a blade-like member descends the foregoing objects will be achieved. How these and other FIG. 2 is an enlarged fragmentary cross sectional view of elements of the apparatus of this invention illustrated in FIG. 10;

FIG. 3 illustrates in partial vertical cross section the actuating mechanism for the loop-forming blade and the gauge blade of the apparatus of this invention;

so as to press warp material, which is continuously supplied to said loop-forming station, between adjacent loop-forming members directly beneath the blade-like member. When the warp material is pressed by the blade-like member between the loop-forming members to form loops of warp material therebetween the blade is withdrawn and the loop-forming members retain the thus-formed loops.

Adjacent and cooperative with the loop-forming station is a gauge blade station which serves the purpose or function of determining the height of the pile in the resulting non-woven fabric or the length of the yarn loops between the loop-forming elements. In operation, before the loop-forming element is moved downwardly to form loops the gauge blade is moved downwardly and inserted between two adjacent loop-forming members containing the immediately previously formed yarn loops. The gauge blade descends thereinto a distance not .grater than and preferablyless than the length or depth of the yarn loop therein. When the gauge blade has entered into the previously formed yarn loops the loop-forming blade descends and produces newly formed yarn loops. In the instance where the gauge blade does not descend into the previously formed yam loops to the full depth of the yarn loops, as the loop-forming blade descends some of the yarn material making up the previously formed yarn loops is taken away or robbed to make up the newly formed yarn loops as the loop-forming blade descends. In effect, therefore, the depth of the gauge blade determines the depth or length of the yarn loops. When the loop-forming blade has fully descended, preferably to a distance greater than the gauge blade, both the loop-forming blade and the gauge blade are removed. The above sequence of operations is carried out and results in the production of a continuous length of non-woven pile fabric, the height of the pile being determined by the distance the gauge blade penetrates into the loop-fonning elements. The gauge blade may be profiled, if desired, to impart a sculptured effect or profile to the resulting pile fabric.

The thus-formed loops are securely retained by and between the loop-forming members as the array of loop-forming members moves. Subsequently, if desired, the loops are cut and an adhesive and/or backing material applied thereto. After a suitable length of travel the loops, now bound to the backing material, are removed from the array of loop-forming members as a substantially finished pile fabric.

The design, fabrication and operation of the array of the slat-like, loop-forming members to yield a commercially acceptable operation and a satisfactory product are difficult, particularly when it is realized that it is commercially desirable to produce continuous length pile fabric having a width of about feet.

The slat-like, loop-forming members making up the closed array must be in closely arranged parallel relationship with the pitch or center-to-center distance between successive loopforming members being approximately three-sixteenth inch, more or less, depending upon the thickness of the yarn. As a result it is apparent that when the slat-like, loop-forming members are long, thin members measuring approximately 15 feet in length they must have substantial depth to prevent sagging. Because of the construction and dimensions of the slat-like, loop-forming members and the resulting array, means must also be provided to provide proper support, alignment and transport of the loop-forming members and the array.

Also, means must be provided for synchronizing the arrival of the slat-like, loop-forming members at the loop-forming station so as to assure proper positioning of the loop-forming members relative to the blade which descends to press the warp material between adjacent loop-forming members to form loops of warp therebetween. If the loop-forming members are disposed and arrayed in a rigid, fixed, parallel, spaced relationship with respect to each other, at best, only a given thickness of warp material or yarn will be accommodated and satisfactorily retained therebetween. Thinner warp material or yarn will tend to leave or escape from between the loop-forming members. Thicker warp material or yarn would require excessive force to force the warp between the loop-forming members. Such excessive force would tend to cause yarn damage and breakage and the resulting formed loops would tend to force to wedge the loop-forming members apart into a non-parallel relationship which would become cumulative such that each succeeding slat-like, loop-forming member would arrive at the loop-forming station with a successively greater tilt until the space available between adjacent loopforming members would become too narrow for continued operation. For example, in the manufacture of a commercially acceptable pile fabric, useful as carpeting, the pitch of the loop-forming members is approximately three-sixteenth inch with about 1} 16 or /s inch spacing between the loop-forming members. Such an arrangement would call for an array of about 68 slat-like, loop-forming members per linear foot of the array. Since the overall closed loop array in accordance with this invention would usually require over a thousand, even thousands, of loop-forming members it should be readily appreciated that even a small cumulative tilt would soon cause the overall apparatus to be inoperative. Even when the slatlike, loop-forming members are disposed in a hinged substantially parallel relationship, which arrangement would require force to be continuously applied to the array so as to retain the looped warp material between the loop-forming members, the total aggregate force required, if supplied from outside the structure by means of springs and the like, becomes enormous and substantially impractical of achievement by such means.

In accordance with this invention, however, the slat-like, loop-forming members are constructed and disposed such that the forces necessary to retain the loop-forming members in the desired array and also to retain the looped warp material therebetween are provided by the loop-forming members per se. Also, in accordance with this invention the slat-like, loopforming members are capable of being readily spread apart to permit the forcing of the warp material therebetween by the descending blade at the loop-fonning station and to yield resiliently and to accommodate various size warp material.

These features are achieved in accordance with this invention by imparting magnetic properties to the slat-like, loopforming members. For example, the slat-like, loop-forming member is made of magnetic material or has magnetic material fixed or otherwise attached thereto such that the loop-forming member attracts adjacent loop-forming members with the result that the array of the loop-forming member is magnetically held together. The magnetic attraction of the loop-forming member to its adjacent loop-forming member provides the force for retaining the looped warp material therebetween. At the same time the magnetic attraction between adjacent loopforrning members permits these members to be, in effect, hingedly separated to readily accommodate the entry of the blade and looped yarn therebetween during the loop-forming operation. This feature of the invention, to which feature is attributable the advantages and the unique operation of the apparatus of this invention, is more clearly and precisely described hereinafter.

Referring now to thedrawings, particularly FIGS. 1a, 1b, and 1c, which illustrate the apparatus and mode of operation of the invention and elements thereof, there is illustrated housing 10 disposed atop and transversely straddling the conveyor system, generally indicated by the reference numeral 11, which is supported by frame 12. Main shaft 14 is mounted and journaled for rotation within housing 10. Eccentric 15 carried on shaft 14 is provided with cam groove 15a in which roller 15b rides. Roller 15b is carried on yoke 16 which pivots on shaft 16a. Shaft 14 is also rotatably fixed to cam 17 which is fixed to yoke 17a which in turn is fixed to yoke 16 by arm 17b and pins 17c.

The rotation of shaft 14 produces an up-and-down motion to rod 18 which is fixed to yoke 17a and at the same time imparts a slight side-to-side motion to rod 18 carried within lower portion 18a of housing 10. Rod 18 is supported by shaft or cylinder 19 within lower portion 18a of housing 10 such that shaft 19 rocks slightly with rod 18 about location 19a within lower housing portion 18a. Push rod 18 is thereby caused to describe a compound motion in the form of a narrow ellipse with a major vertical axis for each complete rotation of main shaft 14 and a minor axis such that the horizontal component or velocity of push rod 18 from left to right as illustrated is relatively small. Loop-forming blade 20 and gauge blade 21, as illustrated, are operatively connected to and fixed to push rod 18 for movement therewith.

Endless conveyor chain 30 carrying loop-forming members 31 is continuously moved by sprockets 32 which in turn are driven by main drive 34 by means of drive chain 35. Sprockets 32 are driven at a uniform speed and move conveyor chain 30 carrying with it the array of loop-forming members 31 in the manner indicated.

Together with the array of loop-forming members 31 which has considerable weight conveyor chain 30 moves along support rail 36 of conveyor frame 12. Support for the lower or returning section of conveyor chain 30 and the lower or returning section of the array of loop-forming members 31 is provided by support chain platform 38 which is shown in greater detail in FIG. 2 wherein support chain platform 38 is shown provided with platform sections 39 at each link 40, thereby making up support chain platform 38. Platform sections 39 assume a fiat, planar conformation directly beneath and in contact with the lower or returning section or array of loop-forming members 31 to support the array and to maintain the loop-forming members 31 straight and without any sagging. Further, support chain platform 38 is mounted like main conveyor chain 30 and moves in synchronism therewith by means of sprockets 41 and drive chain 42. Support chain platform 38 moves and is supported on rail 37 of frame 12 with the result that the weight of the conveyor system carrying the array of loop-forming members 31 is transmitted to frame 12. Rollers 44 rotatably mounted on frame 12 support and guide the lower or returning section of support chain platform 38.

Loop-forming blade and gauge blade 21 are adapted and positioned to descend between adjacent loop-forming members 31 as they move continuously beneath loop-forming blade 20 and gauge blade 21 with the result that warp material 45 isinserted and held between loop-forming members 31 to form loops therebetween.

Warp material 45 is supplied from a suitable source, such as a creel or beam, not shown, through adjustable reed 46 along feed and guide rolls 48 and 48a and through final adjusting reed 49 and guide 50. The synchronization of the downward movement of loop-fonning blade 20 and gauge blade 21 with the motion and position of the loop-forming members 31 as they continuously move by the loop-forming station directly beneath loop-forming blade 20 and gauge blade 21 assures that warp material 45 is inserted downwardly by blade 20 between an adjacent pair of loop-forming members 31 and the immediately previously inserted or looped warp material is held between loop-forming members 31 by gauge blade 21 inserted thereinto. This synchronization may be effected by any suitable means.

As schematically illustrated in FIG. la main shaft 14 is shown driven by main drive 34 via chain 51, differential gear box 52 and chain 54. Main drive 34 is driven by a suitable means, such as electric motor 55. To assist in maintaining the synchronism between downward movement and motion of loop-forming blade 20 and gauge blade 21 and the motion of loop-forming members 31 as they move past the loop-forming station to assure that blades 20 and 21 descend between loopforming members 31 and to compensate for any variations in spacings between loop-forming members 31 in the moving array and to compensate for thermal expansion and the like, a compensating drive system is provided.

In the compensating drive system any additive or subtractive errors in the position of the loop-forming members 31 beneath blades 20 and 21 are detected by sprocket wheel 55 which engages in pinion-like fashion loop-forming members 31 a short distance before the loop-forming station. Sprocket wheel 55 through chain 56 drives rotating reference transducer 58. Errors in the motion and/or position of loop-forming members 31 are detected by sprocket wheel 55 and cause changes in the output signal from transducer 58 proportional to the errors. Signals derived from transducer 58 may be a voltagesignal, a frequency signal or variable quantity. The signal from transducer 58 is sent via line 57 to servocontroller 60 wherein it is compared with another signal received via line 61 and generated by transducer 62 which is actuated via chain drive 64 by the rotational speed of main shaft 14. When the signals supplied to servocontroller 60 are identical in value the operation of the apparatus or machine in accordance with this invention is normal and the synchronism of the motion and position of loop-forming members 31 relative to the motion and position of blades 20 and 21 at the loop-forming station is correct or satisfactory. If the signals are not identical or do not match an appropriate correction output signal is generated by servocontroller 60 and sent via line 65 to servoamplifier 66 wherein it is amplified and sent to servomotor 68 and motor controller 69 to vary the output speed of differential gear box 52. When the difference between the signals compared in servocontroller 60 is eliminated the corrective action ceases.

Rather than driving and controlling the motion and synchronism of the array of loop-forming members 31 and blades 20 and 21 for insertion between adjacent pairs of loop forming members in the manner indicated hereinabove, blades 20 and 21 may be mounted for movement in a vertical direction only. Also, main shaft 14 may be mounted such that it does not continuously rotate but only rotates when space between loop-forming members 31 is available for the insertion of blades 20 and 21. Such a system would comprise a photoelectric cell device of the reflective type including a light source and a detector which senses the presence of the loopforming members and the spaces therebetween due to differences in the amount or other quality of the reflected light. The signal produced by such a photoelectric cell device could operate a relay system which in turn could energize an electromagnetic or other suitable clutch assembly operatively connected to main shaft 14. When actuated, main shaft 14 could be caused to rotate at a high speed for a single rotation only. Blades 20 and 21 would then be actuated to form a single loop-forming cycle, following which they would return to their upper position and await the arrival of the next, successive spaces between loop-forming members 31. Such an arrangement would correct for any errors or variations which may exist in conveyor speed or construction, etc., since the downward motion of blades 20 and 21 would be triggered only by the arrival and detection of available spaces between the loop-forming members 31 at the loop-forming station. By driving main shaft 14 at a sufficiently high speed for a single rotation the loop-forming operation would be completed in an extremely short period of time during which the movement of the array of the continuously moving loop-forming members 31 would be insignificantly small. if desired, however, the array of loop-forming members could be advanced intermittently beneath the loop-forming station in synchronism.

In the operation of the device illustrated in FIGS. 10, 1b and 10 for the manufacture of pile fabric, yarn 45 from a suitable source, such as a beam or creel, not shown, is drawn through adjustable expansion cone or reed 46 and then overfeed and guide rolls 48 and 48a through adjustable expansion reed 49 and between guide plates 50 by the action of blades 20 and 21 which act in combination at the loop-forming station and intermittently descend between loop-fonning members 31 to form loops therebetween. There is thus formed an array of loops from yarn 45 between loop-forming members 31 which moves along with the array of loop-forming members 31.

The array of loops thus formed between the loop-forming members moves beneath carrier beam 26. Carrier beam 26 is fixed to push rod 18 by angle bar 26a and plate 26b. Carrier beam '26 and angle bar 26a are adapted to move in synchronism with rod 18 such that as blades 20 and 21 descend to form a loop of yarn between loop-forming members 31 carrier beam 26 also descends and by means of cutting blade 13 cuts the loops previously formed between loop-form ing members 31. The operation of cutting blade 13 in association with carrier beam 26 is described hereinafter.

Following the formation and cutting of the loops, and referring now to FIG. 1b, suitable film-forming binder material, such as a plastisol, e.g. polyvinyl plastisol, or other thermoplastic material useful as a binder, is distributed by any suitable means such as hopper 71 via rotary distributor device 72 located at the bottom of hopper 71 to apply particle-form thermoplastic material 74 onto sifter or screen 75 or other applicator from which it falls onto the top surface of the array of cut yarns or loops. The resulting plastic coated cut yarns or loops, the top surface of which is covered with thermoplastic binder material 74, such as polyvinyl chloride, including PVC plastisol, polyethylene or polypropylene-containing material and the like, then passes beneath bank 76 of infra-red ray heating elements 78. As the thermoplastic material moves beneath bank 76 of heating elements 78 the thermoplastic material is softened and becomes fluent and tends to coat the top surface of the cut yarn loops with a fluent adhesive layer of plastic material.

Referring now to FIG. 1c, backing material 80, such as burlap, is supplied from roll 81 through feed rolls 82 and guide roll 84 onto the hot fluent thermoplastic material on the top surface of the cut yarn loops. The backing material is then pressed into firm adhesive contact with the hot fluent therlOlOSl 0 moplastic material by means of pressure rolls 85 to form a firm bond between the backing material, the thermoplastic material and the cut yarn loops. Advantageously, pressure rolls 85 are also chilled to set or solidify the fluent thermoplastic adhesive material more quickly. Instead of chilled pressure rolls 85 a chilled pressure plate adapted to be moved in synchronism with the materials being processed can be employed. After a sufficient amount of chilling has been efiected the chilled plate could then be returned to its original position to chill additional material being processed. The size of the chilled plate, the time the chilled plate is in contact with the material being processed and the movement of the material being processed being synchronized so that all the material undergoing processing, i.e. all the backing material, is pressed into contact with the thermoplastic adhesive material and the cut yarn loops. The resulting pile fabric structure 86 comprising cut yarn loops, a coating of thermoplastic material and a backing is removed from the array of loop-forming members 31 by passing under guide roll 88. The pile of fabric is pulled by wind-up roll 89 which is driven in synchronism with sprocket 41 via chain drive 90. Trimming rotary knife blade 91 removes excess pile fabric material and the trimmed pile fabric then moves over guide rolls 92 onto the take-up or wind-up roll 89 from which it is subsequently removed as a substantially finished pile fabric product.

Referring now to FIGS. 3, 4, 5, 6, 7 and FIGS. 8a, 8b, 8c, 8d and 8e, which illustrate the loop-forming operation and the elements thereof in a machine in accordance with this invention, as push rod 18 is moved up-and-down at the loop-forming station in the manner described hereinabove loop-forming blade 20 and gauge blade 21 which are carried on angle bar 26a fixed to push rod 18 are also moved up-and-down. As illustrated in FIG. 3 the lower portion 18a of housing 10 within which push rod 18 operates through cylinder 19 is fixed to housing 10 by screws 18b. Bushing 18c encloses push rod 18 within the lower portion 18a of housing 10 and provides around the upper portion thereof an annular space for the side-to-side rocking motion imparted to push rod 18. The lower end of push rod 18 within the lower portion 18a of housing 10 is positioned therein relative to cylinder 19 by plates 1%.

As further illustrated in FIG. 3 yoke 16 pivots on shaft 16a which is adjustably fixed to plate 16b on the inside of housing 10, plate 16b being fixed to the inside of housing 10 by strap 16c and screws 16d. Shaft 16a is adjustably fixed to plate 16b by means of threaded screw 162 which passes through split portion 16f of plate 16b to adjustably clamp or fix shaft 16a therein.

Referring now particularly to FIGS. 4, 5, 6 and 7, as push rod 18 is moved up-and-down it carries with it angle bar 26a which is fixed to push rod 18 by collars 18d. In turn, angle bar 26a is operatively connected to loop-forming blade 20 and gauge blade 21. Accordingly, as push rod 18 moves up-anddown loop-forming blade 20 and gauge blade 21 also move up-and'down. Loop-forming blade 20 is mounted on carrier 20a and gauge blade 21 is mounted on carrier 2011, being fastened thereto by screws 20b and 21b and plates 20c and 21c, respectively.

Carrier 20a is fixed to a supporting structure on the upper side of angle bar 260. This supporting structure on the upper side of angle bar 26a for the support of carrier 20a and loopforming blade 20 comprises posts 20d with support plate 20e fixed at the upper ends. Threaded rod 20f extends through plate 20c and is fixed to carrier 20a. Spring 20g is biased against knurled collar 20h which is adjustable along threaded rod 20f so as to maintain a firm response for the up-and-down motion of loop-forming blade 20 relative to the up-and-down motion of angle bar 26a, see FIG. 6 for greater detail.

Carrier 21a is fixed to angle bar 26a by means of a supporting structure similar to the supporting structure to which carrier 20a is fixed thereto. This supporting structure for carrier 21a to which gauge blade 21 is fixed is shown in greater detail in FIG. 7 of the drawings. The supporting structure on the upper side of angle bar 260 comprises posts 21d which are fixed to angle bar 26a by screws 21dd. Posts 21d are provided with a supporting plate 21e fixed to the top of posts 21d by screws, not shown. Threaded rod 21 f extends through plate 21e and is fixed at its lower end to carrier 21a. Spring 21g surrounding that portion of threaded rod 21f between plate 21e and carrier 21a serves to maintain a firm response for the upand-down motion of gauge blade 21 relative to the up-anddown motion of angle bar 26a.

The portion of threaded rod 21f above plate 21 is provided at the top thereof with plate 21h which is vertically adjustable along rod 21f by means of nut 21k. The end of the downward motion of rod 21f when moved downwardly by angle bar 26a is adjustably determined by the position of plate 21h along the upper portion of rod 21f.

Channel 22 is fastened to lower portion 18a of housing 10 by means of plate 22a which is fastened thereto by screws 22c. Channel 22 carries on its top resilient buffer pad 22b. The downward motion of rod 21 f when angle bar 260 moves downwardly is terminated when plate 21h contacts buffer pad 22b. The continued downward motion of angle bar 260 after plate 21h contacts buffer pad 22b serves only to move plate 212 downwardly to compress spring 21g.

FIGS. 8a, 8b, 8c, 8d and 8e show the sequence of travel of loop-forming blade 20 and gauge blade 21 at the loop-forming station in the apparatus in accordance with this invention with the resultant production of loops of yarn 45 between loopforming members 31. As illustrated in FIGS. 8a, 8b, and 80, gauge blade 21 precedes loop-forming blade 20. Gauge blade 21 enters the pair of loop-forming members 31 which contain the immediately previously formed loops of yarn. Gauge blade 21 enters part of the way into the previously formed loops of yarn as shown in FIG. 80. Loop-forming blade 20 follows and enters between the preceding pair of loop-forming members 31 to produce therebetween the next set of loops, as illustrated in FIGS. 8d and 8e. As loop-forming blade 20 enters it forms loops of yarn, and in the formation of the loops, yarn material is back-robbed or taken from the previously formed loops of yarn until the previously formed loops of yarn comes into contact with the bottom edge of gauge blade 21. It is thus seen that the depth of penetration of gauge blade 21 between the loop-forming members determines the depth of the yarn loops formed between loop-forming members 31.

FIGS. 9, 10a, 10b and 10c illustrate the loop-cutting operation in the apparatus in accordance with this invention. As illustrated therein carrier beam 26 is fixed to angle bar 26a by means of plate 26b for movement in synchronism with angle bar 26a. On the downward stroke of angle bar 26a carrying with it carrier beam 26 pre-openers which are provided with resilient inserts 121 are moved into contact with looped yarn on top of loop-forming members 31. Pre-openers 120 are swingably mounted in pivot yokes 122. Upon contact with the looped yam on the top of loop-fonning members 31 the downward movement of pre-openers 120 is arrested. The downward movement of carrier beam 26, however, continues and compresses springs 124 which are adjustably set within carrier beam 26 by means of threaded plugs 125. Springs 124 are compressed within carrier beam 26 as carrier beam 26 moves downwardly by the action of piston 126 which bears against the bottom-of springs 124. Piston 126 is fixed to rods 128 which bear on pivot yokes 122.

The upper end of pre-openers 120 are beveled and extend within opening 27 provided within carrier beam 26. Hardened steel ball inserts 129 are provided within opening 27 in carrier beam 26 within which pre-openers 120 project and bear upon the beveled surface of pre-openers 120. As carrier beam 26 moves downwardly compressing springs 124 hardened steel ball inserts 129 ride upon the beveled surfaces of pre-openers 120 causing the lower ends of pre-openers 120 in contact with the looped yarns on loop-forming members 31 to swing outwardly against the urging of pre-loaded springs 130, thereby separating or opening upon the adjacent looped yarn-covered loop-forming members 31 which are in contact with the bottom of pre-openers 120.

As the bottom ends of pre-openers 120 swing out spreading apart loop-forming members 31 knife blade 131 enters the thus-opened space between the open adjacent loop-forming members in contact with pre-openers 120 and cuts the looped yarn therebetween. As illustrated knife blade 131 is carried on and moves with carrier beam 26 by means of shaft 132 and sheaves 134. The sequence of pre-openers 120 contacting the yam-covered loop-forming members 31 and spreading apart loop-fonning members 31 to permit the entry of knife blade 131 therebetween and the withdrawal and subsequent upward motion of knife blade 131 from between loop-forming members 31 and pre-openers 120, as carrier beam 26 moves downwardly and upwardly is illustrated in greater detail in FIGS. 10a, 10b and 100.

As carrier beam 26 is raised knife blade 131 is raised from between loop-forming members 31 and the bottom portions of pre-openers 120 brought together as steel inserts 129 ride up pre-openers 120 to the beveled surfaces thereof. Upon continued upward movement of carrier beam 26 pre'openers 120 are lifted from contact with yarn-covered loop-forming members 31. Carrier beam 26 upon completion of its upward movement is then in position to again move downwardly in synchronism with angle bar 26a so that the loop-forming and the loop-cutting operations are carried out substantially simultaneously during the next downward excursion of angle bar 260.

FIGS. 11a and 11b illustrate one embodiment of the loopcutting apparatus suitable for use in the apparatus in accordance with this invention. As already described herein the loop-cutting apparatus comprises carrier beam 26 which is mounted on and fixed to angle bar 26a which actuates the loop-forming and loop-cutting operations. Carrier beam 26 moves downwardly and upwardly in synchronism with angle bar 260 with the result that the loop-cutting operation performed by the apparatus associated with carrier beam 26 is carried out simultaneously with the loop-forming operation carried out by the apparatus associated with angle bar 26a, all

as described hereinabove.

Carrier beam 26 extends transversely across the array of loop-forming members 31, as illustrated, the array of loopforming members 31 being carried on moving endless conveyor chain 30. The actual loop-cutting is efi'ected by endless knife blade 131 which is carried on guide sheaves 134 fixed to carrier beam 26 by means of shaft 132 and lock nut 133 and driven by drive sheave 135. Drive sheave 135 is driven by motor 136 and flexible belt 138 made of suitable resilient material. Preferably, motor 136 is mounted on a stationary support although, if desired, it may be mounted by means, not shown, fixed to carrier beam 26 so as to move in unison therewith.

As illustrated, endless knife blade 131 driven by drive sheave 135 moves on guide sheaves 134 and between guide rollers 139 which are fixed to carrier beam 26 by suitable means, such as projecting lugs 140.- The upper portion of endless knife blade 13] moves through cut-out portions of carrier beam 26 and the lower portion of blade 131 moves between pre-openers 120. Vertically adjustable mounting 141 provided with vertical setting control knob 141a is provided on carrier beam 26 for holding and positioning conical grinding wheels 142 supported by holder 141b against the cutting edge of knife blade 131, either continuously or intermittently, to effect sharpening of the cutting edge thereof.

Knife blade 131 is under sufficient tension to eliminate any objectionable sag. For example, in a machine calling for the production of endless pile fabric of 15 foot width an endless knife blade having the cross section dimensions 0.75 X 0.025 inch would require a tension of about 100 pounds to eliminate sag. Desirably, the lower portion of knife blade 131 is positioned so as to descend more deeply between loop-forming members 31 than loop-foming blade 20 and/or gauge blade 21 so as to assure cutting of all the loops formed between loop- .forming members 31. Since knife blade 131 is positioned laterally from loop-forming blade 20 and gauge blade 21 only a short, fixed distance, the system for assuring that loop-forming blade 20 and gauge blade 21 descend between adjacent spaced loop-forming members also assures the cutting blade 131 descends between adjacent loop-forming members since any pitch error over this small, fixed distance would be negligible.

As illustrated in FIG. 11a, in order to pass around reasonably small sheaves, knife blade 131 is rotated or twisted when approaching and leaving each end sheave, such as drive sheave 135, by means of free-tuming guide rollers 139.

FIGS. 12, 13, 14 and 15 illustrate the array and assembly of the loop-forming members in accordance with this invention. Loop-forming members 31 comprise an upper cylindrical element 31a and a lower slatlike element 31b. Upper element 31a is supported and spaced from lower element 31b by means of a plurality of post elements 310. Lower element 31b which is shown as having a rectangular cross section is generally a slat-like or bar-like element and carries with it or comprises or is made up of magnetic elements 31d spaced along the length thereof. In a presently preferred embodiment loop-forming members 31 have magnetic elements 31d fixed or otherwise adhesively attached to one side of lower element 31b. With lower element 31b made up of magnetic, permeable material, such as magnetically permeable steel, it is thus seen that the array of loop-forming members 31 illustrated in FIG. 12 is magnetically held together without the need for any external force to keep the array in order. Accordingly, the array of loop-forming members 31 is, in effect, self-energizing.

A further feature is the use of post elements 31c to space the upper element 31a from the lower element 31b thereby providing between adjacent loop-forming members 31 ample spacefor the the looped yarn therebetween with the result that adjacent loop-forming members 31 can accommodate a wide variety of yarn thicknesses without causing overpacking between adjacent loop-forming members 31 during the loopforrning operation.

As illustrated in FIG. 12 the magnetic, self-energizing feature characterizing the array of loop-forming members is provided by means of adhesive plastic magnetic separator strips, such asMinute-man flexible magnetic strip material manufactured by Magnetic Aids, Inc. of New York, N. Y. Such magnetic strip material is made up of magnetic particles embedded in a flexible plastic matrix which is adhesively fastened to one face or side of lower element 31b of loop-forming members 31 with the result that the magnetic strip material or magnetic element 31d is, in effect, sandwiched between two lower elements 31b of loop-forming members 31. The magnetically permeable material making up lower element 31b of loopforming members 31 serves as a shunt to improve the magnetic forces which hold together the array of loop-forming members. If desired, to reduce weight, loop-forming members 31 may be made substantially only of lightweight metal, such as aluminum, which might be clad with a magnetically permeable material, such as steel, on the side surface thereof to which magnetic element 31d is attached.

In accordance with the arrangement illustrated in FIG. 12 each pair or adjacent loop-forming members are self-energizing with the magnetic attractive forces holding together adjacent loop-forming members and the whole array and serving to hold the looped yarn therebetween after the loop-forming operation has been carried out. Also, in effect, adjacent loopforming members 31 act as though they were hingedly attached at the bottom during the loop-forming operation and accordingly accommodate during the loop-forming operation a wide variety of yarn thicknesses.

The array of loop-forming members 31 is mounted on channel strip member encircling conveyor system 11 carrying the array of loop-forming members 31. Channel strip member 150 is made of resilient, flexible material, such as nylon or high durometer neoprene or the like and is provided with channels 151 extending along the length thereof. Each loopfomiing member 31 is keyed to channel strip member 150 by means of spring clip 152, the upper portion of which is attached to bottom element 31b of loop-forming members 31 and the bottom portion of which is keyed within cooperating channel 151 of channel strip 150. As indicated clip 152 can be snapped into position within channel 151 of channel strip 150. Also, as indicated, the position of clip 152 keying alternate loop-forming members 31 is staggered. Also, desirably, as illustrated, the position of alternate post elements 31c of loopforming members 31 is staggered. By this arrangement post elements 31c and clip 152 cause minimal interference with the looped yarns formed between loop-forming members 31 making up the array. Channel strip 150 is secured to two or more roller chains depending upon the width of the pile fabric to be produced. Screws 154 fasten channel strip member 150 to roller chain 30 which comprises undersize rollers 155 and split clamps 156 which are provided with an arcuate upper contour similar to the arc made as split clamps 156 pass over drive sprockets 32.

In the practice of this invention the warp material may include not only yarns made up of natural, synthetic or metallic fibers but also sheets or tapes of such materials, woven and/or non-woven. For example, the warp material may comprise sheet or tape material, such as woven cotton or wool or scrim or woven glass fibers and tapes. The warp material useful in the practice of this invention might also include sheets or tapes of non-woven fibrous material, such as the natural fibrous materials, e.g. cotton fibers, cellulosic fibers, e.g. paper, animal fibers, such as wool fibers, as well as synthetic organic, as well as inorganic fibrous materials, such as polyester fibrous material, e.g. Dacron, rayon fibrous material, cellulose acetate fibrous material, polyolefinic fibrous material, such as polyethylene and polypropylene fibrous materials, acrylic fibrous materials and the inorganic fibrous materials, such as mineral wool, glass fibers and asbestos fibers.

As will be apparent to those skilled in the art in the light of the foregoing disclosure, many modifications, alterations and substitutions are possible in the practice of this invention without departing from the spirit or scope thereof.

lclaim:

1. Apparatus useful for producing a pile fabric comprising an array of loop-forming members, said loop-forming members being disposed in side-by-side relationship, means for supplying warp material transversely onto said array of loopforming members and a loop-forming station in said apparatus, said loop-forming station comprising a loop-forming element adapted for up and down movement relative to said loop-forming members for inserting and pressing downwardly said warp material between a pair of adjacent loop-forming members to form loops of warp material therebetween and a gauge element associated with said loop-forming element, said gauge element also being adapted for up and down movement relative to said loop-forming members, for insertion between a pair of adjacent loop-forming members containing the immediately previously formed loops of warp material to a distance less than the distance said loop-forming element is inserted into said first mentioned pair of loop-forming members so as to maintain said previously formed loops of warp material in position and at a desired depth between said loop-forming members as said loop-forming element is inserted between another pair of said loop-forming members to form additional loops of warp material therebetween.

2. Apparatus in accordance with claim 1 including means for cutting the thus-formed loops of warp material.

3. Apparatus in accordance with claim 1 wherein said loopforrning members are adapted to be magnetically attracted to each other and held together in said array.

4. Apparatus in accordance with claim 1 including means for applying adhesive material to the exposed surfaces of said warp material on said loop-forming members, after said warp material has been depressed between said loop-forming mem bers to form loops therebetween and subsequent to the insertion of said gauge element.

5. Apparatus for producing a pile fabric comprising a closed loop array of loop-forming members, said loop-forming members being disposed in said array in slde-by-side relationship, means for continuously moving said loop-forming members in the path of said array, means for supplying warp material over and transversely with respect to said array of loop-forming members, a loop-forming station, said loop-forming station comprising a loop-forming element adapted for up-and-down movement relative to said loop-forming members for inserting and pressing downwardly said warp material between a pair of adjacent loop-forming members to form loops of warp material therebetween and a gauge element associated with said loop-forming element and adapted for up-and-down movement relative to said loop-forming members, for insertion between a pair of adjacent loop-forming members containing the immediately previously formed loops of warp material to a distance less than the distance said loop-forming element is inserted into said first mentioned pair of loop-forming members so as to maintain said previously formed loops of warp material in position and at a desired depth between said loop-forming members containing the previously formed loops of warp material as said loop-forming element is inserted between another pair of said loop-forming members to form additional loops of warp material therebetween.

6. Apparatus in accordance with claim 5 wherein said loopforming element and said gauge element are blade-like elements.

7. Apparatus in accordance with claim 5 including means for cutting the thus-formed loops of warp material.

8. Apparatus in accordance with claim 5 wherein said loopforming members are magnetically attracted to each other and held together in said array.

9. Apparatus in accordance with claim 5 including means for applying adhesive material to the exposed surfaces of said looped warp material on said loop-forming members after said warp material has been depressed between said loop-forming members to form loops of warp material therebetween and subsequent to the insertion of said gauge element.

10. Apparatus in accordance with claim 5 including means for applying binding material onto the exposed surfaces of portions of said looped warp material disposed and supported on said loop-forming members, the thus-applied binding material serving to bind together the looped warp material and means for removing the thus-formed bound loops of warp material from said array as said pile fabric. 

1. Apparatus useful for producing a pile fabric comprising an array of loop-forming members, said loop-forming members being disposed in side-by-side relationship, means for supplying warp material transversely onto said array of loop-forming members and a loop-forming station in said apparatus, said loop-forming station comprising a loop-forming element adapted for up and down movement relative to said loop-forming members for inserting and pressing downwardly said warp material between a pair of adjacent loop-forming members to form loops of warp material therebetween and a gauge element associated with said loop-forming element, said gauge element also being adapted for up and down movement relative to said loop-forming members, for insertion between a pair of adjacent loop-forming members containing the immediately previously formed loops oF warp material to a distance less than the distance said loop-forming element is inserted into said first mentioned pair of loop-forming members so as to maintain said previously formed loops of warp material in position and at a desired depth between said loop-forming members as said loopforming element is inserted between another pair of said loopforming members to form additional loops of warp material therebetween.
 2. Apparatus in accordance with claim 1 including means for cutting the thus-formed loops of warp material.
 3. Apparatus in accordance with claim 1 wherein said loop-forming members are adapted to be magnetically attracted to each other and held together in said array.
 4. Apparatus in accordance with claim 1 including means for applying adhesive material to the exposed surfaces of said warp material on said loop-forming members, after said warp material has been depressed between said loop-forming members to form loops therebetween and subsequent to the insertion of said gauge element.
 5. Apparatus for producing a pile fabric comprising a closed loop array of loop-forming members, said loop-forming members being disposed in said array in side-by-side relationship, means for continuously moving said loop-forming members in the path of said array, means for supplying warp material over and transversely with respect to said array of loop-forming members, a loop-forming station, said loop-forming station comprising a loop-forming element adapted for up-and-down movement relative to said loop-forming members for inserting and pressing downwardly said warp material between a pair of adjacent loop-forming members to form loops of warp material therebetween and a gauge element associated with said loop-forming element and adapted for up-and-down movement relative to said loop-forming members, for insertion between a pair of adjacent loop-forming members containing the immediately previously formed loops of warp material to a distance less than the distance said loop-forming element is inserted into said first mentioned pair of loop-forming members so as to maintain said previously formed loops of warp material in position and at a desired depth between said loop-forming members containing the previously formed loops of warp material as said loop-forming element is inserted between another pair of said loop-forming members to form additional loops of warp material therebetween.
 6. Apparatus in accordance with claim 5 wherein said loop-forming element and said gauge element are blade-like elements.
 7. Apparatus in accordance with claim 5 including means for cutting the thus-formed loops of warp material.
 8. Apparatus in accordance with claim 5 wherein said loop-forming members are magnetically attracted to each other and held together in said array.
 9. Apparatus in accordance with claim 5 including means for applying adhesive material to the exposed surfaces of said looped warp material on said loop-forming members after said warp material has been depressed between said loop-forming members to form loops of warp material therebetween and subsequent to the insertion of said gauge element.
 10. Apparatus in accordance with claim 5 including means for applying binding material onto the exposed surfaces of portions of said looped warp material disposed and supported on said loop-forming members, the thus-applied binding material serving to bind together the looped warp material and means for removing the thus-formed bound loops of warp material from said array as said pile fabric. 